Teledyne 3190 User Manual
OPERATING INSTRUCTIONS
FOR
Model 3190 Series
Trace Oxygen Analyzer
DANGER
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A
TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/MANAGER.
Teledyne Analytical Instruments
P/N M64641
06/21/2000
ECO # 00-0221
i
Copyright © 1999 Teledyne Analytical Instruments
All Rights Reserved. No part of this manual may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any other language or computer
language in whole or in part, in any form or by any means, whether it be electronic,
mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of
Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-
1580.
Warranty
This equipment is sold subject to the mutual agreement that it is warranted by us
free from defects of material and of construction, and that our liability shall be limited to
replacing or repairing at our factory (without charge, except for transportation), or at
customer plant at our option, any material or construction in which defects become
apparent within one year from the date of shipment, except in cases where quotations or
acknowledgements provide for a shorter period. Components manufactured by others bear
the warranty of their manufacturer. This warranty does not cover defects caused by wear,
accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and
the purchaser by the acceptance of the equipment will assume all liability for any damage
which may result from its use or misuse.
We reserve the right to employ any suitable material in the manufacture of our
apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in
so far as such alterations do not adversely affect our warranty.
Important Notice
This instrument provides measurement readings to its user, and serves as a tool by
which valuable data can be gathered. The information provided by the instrument may
assist the user in eliminating potential hazards caused by his process; however, it is
essential that all personnel involved in the use of the instrument or its interface, with the
process being measured, be properly trained in the process itself, as well as all instrumentation related to it.
The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent
danger, it has no control over process conditions, and it can be misused. In particular, any
alarm or control systems installed must be tested and understood, both as to how they
operate and as to how they can be defeated. Any safeguards required such as locks, labels,
or redundancy, must be provided by the user or specifically requested of Teledyne at the
time the order is placed.
Therefore, the purchaser must be aware of the hazardous process conditions. The
purchaser is responsible for the training of personnel, for providing hazard warning
methods and instrumentation per the appropriate standards, and for ensuring that hazard
warning devices and instrumentation are maintained and operated properly.
Teledyne Analytical Instruments (TAI), the manufacturer of this instrument,
cannot accept responsibility for conditions beyond its knowledge and control. No
statement expressed or implied by this document or any information disseminated by the
manufacturer or its agents, is to be construed as a warranty of adequate safety control
under the user’s process conditions.
ii Teledyne Analytical Instruments
Specific Model Information
The instrument for which this manual was supplied may incorporate one or
more options not supplied in the standard instrument. Commonly available
options are listed below, with check boxes. Any that are incorporated in the
instrument for which this manual is supplied are indicated by a check mark in the
box.
Instrument Serial Number: _______________________
Options Included in the Instrument with the Above Serial Number:
❑❑
❑ Class A-2C Micro-Fuel Cell: For 0-100% CO
❑❑
Purpose (range 0-10 ppm O2 minimum).
❑❑
❑ Class B-2C Micro-Fuel Cell: For General Purpose and high hydrogen
❑❑
or helium backgrounds (range 0-10 ppm
O2 minimum).
background and General
2
❑❑
❑ Class Z-2C Micro-Fuel Cell: For faster recovery after air calibration
❑❑
(range 0-200 ppm O2 minimum).
Class B-2C is the standard cell provided.
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iii
Contents
Introduction
1.1 Overview ........................................................................ 1-1
1.2 Main Features of the Analyzer ....................................... 1-1
1.3 Front Panel Description.................................................. 1-2
1.4 Rear Panel Description .................................................. 1-3
Operational Theory
2.1 Introduction .................................................................... 2-1
2.2 Micro-Fuel Cell Sensor .................................................. 2-1
2.2.1 Principles of Operation .......................................... 2-1
2.2.2 Anatomy of a Micro-Fuel Cell................................. 2-2
2.2.3 Electrochemical Reactions .................................... 2-3
2.2.4 The Effect of Pressure............................................ 2-4
2.2.5 Calibration Characteristics ..................................... 2-4
2.3 Electronics ..................................................................... 2-5
2.3.1 General .................................................................. 2-5
2.3.2 Signal Processing .................................................. 2-5
Installation
3.1 Unpacking the Analyzer ................................................. 3-1
3.2 Location and Mounting .................................................. 3-2
3.2.1 Control Unit Installation.......................................... 3-2
3.2.2 External Probe Installation ..................................... 3-2
3.2.3 Installing the Micro-Fuel Cell ................................. 3-3
3.3 Electrical Connections ................................................... 3-3
3.4 Gas Connections ........................................................... 3-7
3.5 Installation Checklist ...................................................... 3-7
Operation
4.1 Introduction .................................................................... 4-1
4.2 Using the Function and Data Entry Buttons ................... 4-2
4.3 Setting the Analysis Ranges .......................................... 4-2
4.3.1 HI Range ............................................................... 4-3
4.3.2 LO Range .............................................................. 4-3
4.3.3Settle Mode ............................................................... 4-3
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4.4 Setting the Alarm Setpoints............................................ 4-3
4.4.1 HI Alarm ................................................................. 4-3
4.4.2 LO Alarm ................................................................ 4-3
4.4.3 Sensor Fail Alarm .................................................. 4-4
4.5 Selecting a Fixed Range or Autoranging ....................... 4-4
4.6 Calibration ..................................................................... 4-4
4.7 Displaying Percent & PPM on the LED Display ............. 4-5
4.8 "SetL" mode in the LED display ..................................... 4-6
Maintenance
5.1 Replacing the Fuse ........................................................ 5-1
5.1.1 AC Powered Units ................................................. 5-1
5.1.2 DC Powered Units ................................................. 5-2
5.2 Sensor Installation or Replacement ............................... 5-2
5.2.1 When to Replace a Sensor .................................... 5-2
5.2.2 Ordering and Handling of Spare Sensors .............. 5-3
5.2.3 Removing the Micro-Fuel Cell ............................... 5-3
5.2.4 Installing a Micro-Fuel Cell .................................... 5-4
5.2.5 Cell Warranty Conditions ....................................... 5-5
Appendix
A.1 Specifications ................................................................ A-1
A.2 Spare Parts List ............................................................. A-2
A.3 Drawing List ................................................................... A-3
A.4 Miscellaneous ................................................................ A-3
A.5 Material Safety Data Sheet ............................................ A-4
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vi Teledyne Analytical Instruments
Trace Oxygen Analyzer Introduction 1
Introduction
1.1 Overview
The Teledyne Analytical Instruments (TAI) Model 3190 is a microprocessor-based trace oxygen analyzer for real-time measurement of trace
amounts of oxygen in inert gases, or in a wide variety of gas mixtures. It
features simple operation, fast response, and a compact, rugged construction.
Typical applications of the Model 3190 are monitoring nitrogen generators
and inert gas blanketing applications.
1.2 Main Features of the Analyzer
The main features of the analyzer include:
• High resolution, accurate readings of oxygen content from
0-10 ppm through 0-25 %. Large, bright, light-emitting-diode
meter readout.
• Simple pushbutton controls.
• Nylon cell holder.
• Advanced Micro-Fuel Cell, for trace analysis, has a six (6)
months warranty and expected lifetime.
• Unaffected by oxidizable gases.
• Fast response and recovery time.
• Microprocessor based electronics: 8-bit CMOS microprocessor
with on-board RAM and 16 kB ROM.
• Two user selectable ranges (from 0-10 ppm through
0-9,999 ppm) allow best match to users process and equipment.
• Air-calibration range for convenient spanning at 20.9 %.
• Operator can select Autoranging, which allows the analyzer to
automatically select the proper preset range for a given
measurement, or he can lock the analyzer onto a single range.
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1-1
1 Introduction Model 3190
• Two concentration alarms with adjustable setpoints.
• Sensor failure alarm.
• RS-232 serial digital port for output of concentration and range
data to a computer, terminal, or other digital device.
• Three analog outputs: two for measurement (0–10 V dc, and
negative ground 4–20 mA dc) and one for range identification
(0-10 V dc).
• Compact and rugged Control Unit with flush-panel case.
Designed for indoor use. Front panel NEMA-4 rated.
• External Probe can be located six feet or more away, depending
on the existing electromagnetic noise level.
1.3 Front Panel Description
All controls and displays except the power switch are accessible from
the front panel. See Figure 1-1. The front panel has seven pushbutton membrane switches, a digital meter, and an alarm indicator LED for operating the
analyzer. These features are described briefly here and in greater detail in
Chapter 4, Operation.
Figure 1-1: Front Panel
Function Keys: Seven pushbutton membrane switches are used to
select the function performed by the analyzer:
1-2
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Trace Oxygen Analyzer Introduction 1
• Set HI Alarm Set the concentration ABOVE which an
alarm activates.
• Set LO Alarm Set the concentration BELOW which an
alarm activates.
• Set HI Range Set the high analysis range for the instrument
(up to 0-9999 ppm).
• Set LO Range Set the low analysis range for the instrument
(down to 0-10 ppm).
• Span Span calibrate the analyzer.
Data Entry Keys: Two pushbutton membrane switches are used to
manually change measurement parameters of the instrument as they are
displayed on the LED meter readout:
• Up Arrow Increment values of parameters upwards as
they are displayed on the LED readout.
• Down Arrow Increment values of parameters downwards as
they are displayed on the LED readout.
Digital LED Readout: The digital display is a LED device that
produces large, bright, 7-segment numbers that are legible in any lighting
environment. It has two functions:
• Meter Readout: As the meter readout, it displays the oxygen
concentration currently being measured.
• Measurement Parameters Readout: It also displays user-
definable alarm setpoints, ranges, and span calibration point
when they are being checked or changed.
1.4 Rear Panel Description
The rear panel contains the electrical input and output connectors.
Separate rear panel illustrations are shown in Figure 1-2 for the AC and DC
powered versions of the instrument. The connectors are described briefly
here and in detail in the Installation chapter of this manual.
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1 Introduction Model 3190
1-4
Figure 1-2 Rear Panel (AC and DC versions)
• Power Connection AC version: 100–240 V ac, at 50/60 Hz.
The connector housing includes the fuse
holder and the power switch.
DC version: Requires between 10 and
36 V dc.
Fuse Holder: Replacing the fuse is
described in Chapter 5, Maintenance.
I/O Power Switch: Turns the instrument
power ON (1) or OFF (0).
• Analog Outputs 0–10 V dc concentration output.
0–10 V dc range ID (or optional
overrange) output.
4–20 mA dc concentration output,
negative ground.
Teledyne Analytical Instruments
Trace Oxygen Analyzer Introduction 1
• Alarm Connections HI Alarm, LO Alarm, and Sensor Failure
Alarm connections.
• RS-232 Port Serial digital output of concentration and
range signals.
• External Probe Connects to the Remote Probe or remote
Analysis Unit.
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1 Introduction Model 3190
1-6
Teledyne Analytical Instruments
Trace Oxygen Analyzer Operational Theory 2
Operational Theory
2.1 Introduction
The analyzer is composed of two subsystems:
1. Analysis Unit with Micro-Fuel Cell Sensor
2. Control Unit with Signal Processing, Display and Controls
The Analysis Unit is designed to accept the sample gas and direct it to
the sensitive surface of the Micro-Fuel Cell sensor. The Micro-Fuel Cell is
an electrochemical galvanic device that translates the amount of oxygen
present in the sample into an electrical current.
The Control Unit processes the sensor output and translates it into
electrical concentration, range, and alarm outputs, and a trace oxygen
meter readout. It contains a microcontroller that manages all signal processing, input/output, and display functions for the analyzer.
2.2 Micro-Fuel Cell Sensor
2.2.1 Principles of Operation
The oxygen sensor used in the Model 3190 is a Micro-Fuel Cell
designed and manufactured by TAI. It is a sealed, disposable electrochemical transducer.
The active components of the Micro-Fuel Cell are a cathode, an
anode, and the 15 % aqueous KOH electrolyte in which they are immersed.
The cell converts the energy from a chemical reaction into an electrical
current through an external electrical circuit. Its action is similar to that of
a battery.
There is, however, an important difference in the operation of a
battery as compared to the Micro-Fuel Cell: In the battery, all reactants are
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